Three-dimensional curved brick arch splicing unit, three-dimensional curved vault system and manufacturing method

Abstract

The application discloses a three-dimensional curved brick arch splicing unit, a three-dimensional curved vault system and a manufacturing method, relates to the technical field of assembled vaults, and comprises a three-dimensional curved brick arch body, a plurality of soft connecting pieces and a keel frame. The three-dimensional curved brick arch body comprises a three-dimensional curved brick body and a UHPC high-strength concrete pouring body. The three-dimensional curved brick body is a three-dimensional curved surface formed by splicing a plurality of brick bodies. Filling intervals are arranged between the brick bodies. The UHPC high-strength concrete pouring body is used for integrally pouring the outside of the three-dimensional curved brick body and the filling intervals. The bottom end of each soft connecting piece is embedded and fixed to the top of the three-dimensional curved brick arch body, and the top end is used for being connected with the bottom of the keel frame. The top of the keel frame is used for being connected with a concrete main body structure. The application forms an assembled prefabricated part by pouring UHPC high-strength concrete on the brick body. The structure is simple, the construction is convenient, the integrity is good, the curved surface is smooth, the precision is high, the self weight is light, and the cost is effectively reduced.

Description

Technical Field

[0001] This invention relates to the field of prefabricated arch technology, and in particular to a three-dimensional curved brick arch splicing unit, a three-dimensional curved arch system, and a manufacturing method. Background Technology

[0002] Existing three-dimensional curved brick arch systems are primarily implemented using sintered brick masonry. Precise measurements and meticulous masonry techniques are required to ensure the accuracy of the brickwork and the integrity of the structure. Furthermore, attention must be paid to the tightness of the brickwork during construction to ensure its stability. Three-dimensional curved brick arches implemented using masonry methods have a large overall mass, limited spatial dimensions, and require additional reinforcement at their boundaries.

[0003] Existing three-dimensional curved brick arch systems also utilize dry-hanging systems. In dry-hanging systems, each brick requires metal components to connect to the keel, resulting in numerous components and a large overall weight. To achieve a perfect curved surface, high-precision subdivision is required, leading to small, numerous modules and high costs. Summary of the Invention

[0004] The purpose of this invention is to provide a three-dimensional curved brick arch splicing unit, a three-dimensional curved arch roof system and manufacturing method to solve the problems existing in the prior art. It has a simple structure, convenient construction, good integrity, smooth curved surface, high precision, light weight and effectively reduces costs.

[0005] To achieve the above objectives, the present invention provides the following solution:

[0006] This invention provides a three-dimensional curved brick arch splicing unit, comprising: a three-dimensional curved brick arch body, multiple flexible connectors, and a keel frame. The three-dimensional curved brick arch body includes three-dimensional curved bricks and UHPC high-strength concrete castings. The three-dimensional curved bricks are a three-dimensional curved surface formed by splicing multiple bricks, and filling intervals are provided between each brick. The UHPC high-strength concrete castings are integrally cast on the outer side of the three-dimensional curved bricks and each filling interval. The bottom end of each flexible connector is embedded and fixed to the top of the three-dimensional curved brick arch body. The top of the keel frame is used to connect with the concrete main structure, and the bottom of the keel frame is used to connect with the end of each flexible connector away from the three-dimensional curved brick arch body.

[0007] Preferably, a U-shaped dovetail groove is provided on the outer side of the brick body. The U-shaped dovetail groove is connected to the filling interval. The U-shaped dovetail groove includes a first vertical groove, a second vertical groove, and a horizontal groove. The horizontal groove is located at the bottom of one side of the brick body and is connected to the bottom surface of the brick body. The bottom of the first vertical groove is connected to one end of the horizontal groove and the other end is connected to the top surface of the brick body. The bottom of the second vertical groove is connected to the end of the horizontal groove away from the first vertical groove and the other end is connected to the top surface of the brick body.

[0008] Preferably, the UHPC high-strength concrete casting body includes a first casting body, a second casting body, and a third casting body. The first casting body, the second casting body, and the third casting body are integrally cast and are all made of UHPC high-strength concrete. The first casting body is disposed in the filling interval to connect adjacent bricks. The second casting body is cast in the U-shaped dovetail groove. The third casting body is cast on the outside of the three-dimensional curved brick body.

[0009] Preferably, the thickness of the third casting body is 20-30 mm.

[0010] Preferably, it also includes multiple UHPC reinforcing wrappers and multiple connecting bolts. The top of the flexible connector is provided with a connecting hole. The UHPC reinforcing wrapper is cast and wrapped around the portion of the flexible connector that protrudes from the UHPC high-strength concrete casting and is fused and fixedly connected to the UHPC high-strength concrete casting. The connecting bolt passes through the connecting hole and is fixedly connected to the keel frame. The diameter of the connecting hole is larger than the diameter of the connecting bolt.

[0011] Preferably, the keel frame is welded from bidirectional square steel pipes.

[0012] Preferably, the system also includes multiple metal rods, the bottom end of which is used for fixed connection with the keel frame, and the top end of which is used for fixed connection with the concrete main structure.

[0013] Preferably, the top end of the metal hanger is connected to the concrete body by means of fixing through the structural plate, fixing by welding of embedded parts, or fixing with post-installed expansion bolts.

[0014] The present invention also provides a three-dimensional curved arch system, comprising a plurality of three-dimensional curved brick arch splicing units as described in any of the preceding claims.

[0015] The present invention also provides a method for manufacturing the three-dimensional curved surface arch system as described above, comprising the following steps:

[0016] S1: Lay a large mold base plate on the horizontal site of the component factory, and build CNC-carved stiffening plates on the large mold base plate to form the mold;

[0017] S2. The bricks are assembled on the mold according to the designed brick arrangement scheme, and rubber strips are fixed between adjacent bricks to form a filling gap between the bricks.

[0018] S3. Embed flexible connectors, and pour UHPC high-strength concrete layer by layer between the bricks on the side away from the mold to form the UHPC high-strength concrete casting body.

[0019] S4. Connect the flexible connector to the keel steel frame;

[0020] S5. After the UHPC high-strength concrete pouring body has completely solidified, the keel steel frame is lifted for demolding. After demolding, the rubber strip is removed and the grout leakage on the surface of the brick body is cleaned.

[0021] S6. Transport the completed three-dimensional curved brick arch splicing unit to the location where it needs to be installed, and connect the keel frame to the main concrete structure.

[0022] The present invention achieves the following technical effects compared to the prior art:

[0023] This invention provides a three-dimensional curved brick arch splicing unit, a three-dimensional curved arch roof system, and a manufacturing method. It includes assembling multiple masonry pieces to form a three-dimensional curved brick body, and then pouring UHPC high-strength concrete into the filling gaps between the masonry pieces and on the outer side of the masonry pieces to form a UHPC high-strength concrete casting body. This UHPC high-strength concrete casting body connects the various masonry pieces into a whole, forming the three-dimensional curved brick arch body. The three-dimensional curved brick arch body is connected to a keel frame through multiple flexible connectors, and then the keel frame is connected to the main concrete structure. The structure is simple, has better overall integrity, is more convenient to construct, has a smooth curved surface, high precision, and light weight, effectively reducing costs. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 A cross-sectional view of the three-dimensional curved brick arch splicing unit provided by the present invention;

[0026] Figure 2 This is a front view of the brick body in the three-dimensional curved brick arch splicing unit provided by the present invention;

[0027] Figure 3 This is a schematic diagram of the structure in which the metal hanger and the concrete body are fixed by means of a through-structure plate in the three-dimensional curved brick arch splicing unit provided by the present invention.

[0028] Figure 4 This is a schematic diagram of the structure in which the metal hanger is fixed to the concrete body by welding with embedded parts in the three-dimensional curved brick arch splicing unit provided by the present invention.

[0029] Figure 5This is a schematic diagram of the structure in which the metal hanger and the concrete body are fixed by a post-installed expansion bolt in the three-dimensional curved brick arch splicing unit provided by the present invention.

[0030] Figure 6 This is a top view of the three-dimensional curved surface arch system in Example 2;

[0031] Figure 7 This is a cross-sectional view of the three-dimensional curved surface arch system in Example 2;

[0032] Figure 8 This is a brick layout diagram of the top slab of the three-dimensional curved surface arch system example in Embodiment 2;

[0033] Figure 9 This is a partial development view of the three-dimensional curved surface arch system in Example 2;

[0034] Figure 10 This is a partial brickwork diagram of the column in the three-dimensional curved arch system of Example 2;

[0035] In the diagram: 100, Three-dimensional curved brick arch splicing unit; 1, Three-dimensional curved brick arch body; 2, UHPC high-strength concrete casting body; 3, Flexible connector; 4, Keel frame; 5, Bolt; 6, Metal hanger; 7, Concrete main structure; 8, Brick body; 9, U-shaped dovetail groove; 10, First vertical groove; 11, Second vertical groove; 12, Horizontal groove; 14, Column. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] The purpose of this invention is to provide a three-dimensional curved brick arch splicing unit, a three-dimensional curved arch roof system and manufacturing method to solve the problems existing in the prior art. It has a simple structure, convenient construction, good integrity, smooth curved surface, high precision, light weight and effectively reduces costs.

[0038] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0039] Example 1

[0040] This embodiment provides a three-dimensional curved brick arch splicing unit, such as... Figures 1-5As shown, it includes: a three-dimensional curved brick arch body 1, multiple flexible connectors 3, and a keel frame 4. The three-dimensional curved brick arch body 1 includes three-dimensional curved bricks 8 and UHPC high-strength concrete casting bodies 2. The three-dimensional curved bricks 8 are three-dimensional curved surfaces assembled from multiple bricks 8, with filling gaps between each brick 8. The UHPC high-strength concrete casting body 2 is used to integrally cast on the outside of the three-dimensional curved bricks 8 and each filling gap. The UHPC high-strength concrete is poured to form the UHPC high-strength concrete casting body 2. After solidification through the flow, penetration, and absorption of the UHPC high-strength concrete, it forms a whole, namely the three-dimensional curved brick arch body 1. UHPC high-strength concrete has high flowability, high strength, good self-compacting performance, and good toughness. One end of each flexible connector 3 is embedded and fixed to the three-dimensional curved brick arch body 1. The top of the three-dimensional curved brick arch body 1; the top of the keel frame 4 is used to connect with the concrete main structure 7, and the bottom of the keel frame 4 is used to connect with the end of each connector away from the three-dimensional curved brick arch body 1. Multiple masonry are assembled to form a three-dimensional curved brick body 8, and UHPC high-strength concrete is poured in the filling gaps between each masonry and on the outside of the masonry to form a UHPC high-strength concrete casting body 2. Thus, the UHPC high-strength concrete casting body 2 connects each masonry into a whole to form the three-dimensional curved brick arch body 1. The three-dimensional curved brick arch body 1 is connected to the keel frame 4 through multiple flexible connectors, and then the keel frame 4 is connected to the concrete main structure 7. The structure is simple, the integrity is better, the construction is more convenient, the curved surface is smooth, the precision is high, the self-weight is light, and the cost is effectively reduced.

[0041] In a preferred embodiment, a U-shaped dovetail groove 9 is provided on the outer side of the brick body 8. The U-shaped dovetail groove 9 is connected to the filling interval. The U-shaped dovetail groove 9 includes a first vertical groove 10, a second vertical groove 11, and a horizontal groove 12. The horizontal groove 12 is located at the bottom of one side of the brick body 8 and is connected to the bottom surface of the brick body 8. The bottom of the first vertical groove 10 is connected to one end of the horizontal groove 12 and the other end is connected to the top surface of the brick body 8. The bottom of the second vertical groove 11 is connected to the end of the horizontal groove 12 away from the first vertical groove 10 and the other end is connected to the top surface of the brick body 8. By providing the U-shaped dovetail groove 9, the brick body 8 and the UHPC high-strength concrete casting body 2 can be better embedded, effectively improving the integrity of the three-dimensional curved brick arch body 1.

[0042] In a preferred embodiment, the UHPC high-strength concrete casting body 2 includes a first casting body, a second casting body, and a third casting body. The first casting body, the second casting body, and the third casting body are integrally cast and all are made of UHPC high-strength concrete. The first casting body is placed in the filling interval to connect adjacent bricks 8. The second casting body is cast in the U-shaped dovetail groove 9. The third casting body is cast on the outside of the three-dimensional curved brick 8. The first casting body is used to bond adjacent bricks 8, and the second casting body is used to increase the embedding effect between the brick 8 and the third casting body, thereby effectively improving the overall integrity.

[0043] In a preferred embodiment of this invention, the thickness of the third casting body is 20-30 mm.

[0044] In a preferred embodiment, the three-dimensional curved brick arch splicing unit further includes multiple UHPC reinforcing wrappers and multiple connecting bolts. The flexible connectors are metal parts with connecting holes at their tops. The connecting bolts pass through the connecting holes and are fixedly connected to the keel frame. The diameter of the connecting holes is larger than the diameter of the connecting bolts, allowing for a flexible connection between the metal parts and the keel frame. The UHPC reinforcing wrappers are cast and wrapped around the portion of the flexible connector that protrudes from the UHPC high-strength concrete casting and are fused and fixedly connected to the UHPC high-strength concrete casting. The thickness of the UHPC reinforcing wrappers is 20-30mm. The UHPC reinforcing wrappers enhance the stability of the connection between the metal parts and the UHPC high-strength concrete casting. The UHPC reinforcing wrappers are formed by casting UHPC high-strength concrete on the portion of the metal parts that protrudes from the UHPC high-strength concrete casting before the initial setting of the UHPC high-strength concrete casting.

[0045] In a preferred embodiment, the keel frame 4 is welded from bidirectional square steel tubes, which has a simple structure, is easy to source materials, and ensures the uniformity of the distribution of hanging points.

[0046] In a preferred embodiment, the shape of the three-dimensional curved brick arch body 1 is a three-dimensional curved surface formed by the intersection of two curved surfaces.

[0047] In a preferred embodiment, the three-dimensional curved brick arch splicing unit further includes multiple metal hangers 6. The bottom end of the metal hanger 6 is used to fix it to the keel frame 4, and the top end of the metal hanger 6 is used to fix it to the concrete main structure 7. The metal hangers 6 are evenly arranged to ensure that the overall weight of the three-dimensional curved brick arch body 1 is evenly distributed on each metal hanger.

[0048] In a preferred embodiment, the top of the metal rod 6 is connected to the concrete body by means of fixing through the structural plate, welding of embedded parts, or fixing with post-installed expansion bolts 5.

[0049] Example 2

[0050] This embodiment also provides a three-dimensional curved surface arch system, such as Figures 6-10 As shown, it includes multiple three-dimensional curved brick arch splicing units as in Embodiment 1, a foundation, and a concrete main structure 7. The bottom of the three-dimensional curved brick arch body is connected to the foundation, and the top of the three-dimensional curved brick arch body is connected to the keel frame 4 through connectors. The keel frame 4 is connected to the concrete main structure 7, as shown. Figure 6 As shown, the three-dimensional curved arch system is composed of four three-dimensional curved brick arch splicing units. Figure 7 The bottom corner support of the three-dimensional curved brick arch splicing unit is shown on column 14. Figure 8 This document displays an example of a prefabricated sintered brick reverse-molded three-dimensional curved arch roof, showing the unfolded layout of the top slab bricks. Figure 9 This shows a partial unfolded view of the vault of the three-dimensional curved surface vault system. Figure 10 A partial brickwork diagram of column 14 in a three-dimensional curved arch system is presented. Example

[0051] This embodiment also provides a method for manufacturing a three-dimensional curved surface arch system as described in Embodiment 2.

[0052] S1. First, according to the design requirements, the curved arches of each shape are modeled using BIM software. The stiffening plates are then CNC-carved using latitude and longitude lines. A large mold base plate is laid on the horizontal site of the component factory, and the CNC-carved stiffening plates are built on the large mold base plate to form the mold. Then, the surface of the mold is treated and shaped by using wood boards, putty, sanding, etc.

[0053] S2. Within the stabilized large mold, decorative bricks 8 are arranged according to the predetermined bricklaying scheme. Rubber strips are placed in the joints between the decorative bricks and bound with steel wire. The rubber strips are positioned between adjacent bricks, close to the inner side of the three-dimensional curved brick arch body, to create filling gaps between adjacent bricks. These filling gaps connect to U-shaped dovetail grooves 9. The rubber strips create filling gaps between adjacent bricks 8 vertically and horizontally, allowing UHPC high-strength concrete to be poured within these gaps to connect adjacent bricks 8. Furthermore, the rubber strips seal the end of the filling gap near the inner side of the three-dimensional curved brick arch body, preventing UHPC high-strength concrete from flowing out from the inner side of the three-dimensional curved brick arch body during pouring. The rubber strips are placed between the bricks 8 and connected to them with wire. The selected decorative bricks are then systematically assembled onto the mold according to the predetermined design effect, completing the initial design form. The entire production process combines manual labor and machinery, ensuring standardized dimensions and high precision, achieving the standards of fine decoration. To increase the bonding surface and reduce the weight of the brick, U-shaped dovetail grooves are cut on the brick surface to ensure the firmness of the cast body;

[0054] S3. Uniformly pour UHPC high-strength concrete layer by layer onto the back of the three-dimensional curved brick body. UHPC high-strength concrete is a new material that has emerged in recent years; it is an ultra-high-strength cement-based material with high strength, high toughness, and low porosity. Its basic formulation principle is to reduce the porosity and micro-cracks within the material by increasing the fineness and activity of the components and eliminating the use of coarse aggregate, thereby achieving ultra-high strength and high durability. Its main components are quartz sand, water-reducing agent, polymer, fine aggregate, and high-performance modifier. Its characteristics are high strength, high toughness, durability, rapid setting, and strong plasticity. Use a special spray gun to uniformly pour the pre-mixed UHPC high-strength concrete onto the back of the assembled brick body 8. The pouring process should be uniform, with each layer gradually increasing in thickness, until the final thickness is 20-30mm.

[0055] S4. The length of the flexible connector is calculated by simulation on the model. Before the initial setting of the UHPC high-strength concrete pouring body, the metal part is inserted at the corresponding position, and UHPC high-strength concrete is poured again within 20~30mm of the metal part extending out of the UHPC high-strength concrete pouring body.

[0056] S5. Weld the keel steel frame in advance, and connect the metal parts to the keel steel frame one by one using connecting bolts 5.

[0057] S6. Let it stand for more than 24 hours until the UHPC high-strength concrete has completely solidified, then it can be lifted and demolded. Begin cleaning the surface of the sintered bricks to remove any grout leakage and contamination.

[0058] S7. Transport the completed three-dimensional curved brick arch splicing unit to the installation location, and use metal hangers 6 to hoist it onto the main concrete structure 7. The fixing methods include fixing through the structural plate, fixing by welding of embedded parts, and fixing with post-installed expansion bolts 5.

[0059] The beneficial effects of this invention are as follows: The precast sintered brick inverted ceiling system employs a combination of masonry bonding and hanging techniques, resulting in accurate curvature, natural connections, high prefabrication rates, material savings, reduced construction waste, and shorter construction periods. The precast modules are made of UHPC concrete, enabling larger masonry modules with better overall integrity and easier construction. The prefabricated sintered brick inverted three-dimensional curved arch system exhibits the effect of a perfect solid brick arch while also achieving versatility in scale and applicable spaces. Different scales and module division methods can be used according to different spatial requirements, and the bricks can be arranged in different ways. Materials can be either machine-made or handmade bricks. It can be used not only for interior and exterior buildings but also for structures, landscaping, and other applications, showcasing the characteristics of different building types and spaces. Its applications are very wide-ranging.

[0060] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A three-dimensional curved brick arch splicing unit, characterized in that: include: The three-dimensional curved brick arch body includes a three-dimensional curved brick body and a UHPC high-strength concrete casting body. The three-dimensional curved brick body is a three-dimensional curved surface composed of multiple bricks, and there are filling gaps between each brick. The UHPC high-strength concrete casting body is used to be cast integrally on the outside of the three-dimensional curved brick body and each filling gap. Multiple flexible connectors, the bottom end of each of which is embedded and fixed to the top of the three-dimensional curved brick arch body; and The keel frame, the top of which is used to connect with the main concrete structure, and the bottom of which is used to connect with the end of each of the flexible connectors away from the three-dimensional curved brick arch body. A U-shaped dovetail groove is provided on the outer side of the brick body. The U-shaped dovetail groove is connected to the filling interval. The U-shaped dovetail groove includes a first vertical groove, a second vertical groove, and a horizontal groove. The horizontal groove is located at the bottom of one side of the brick body and is connected to the bottom surface of the brick body. The bottom of the first vertical groove is connected to one end of the horizontal groove and the other end is connected to the top surface of the brick body. The bottom of the second vertical groove is connected to the end of the horizontal groove away from the first vertical groove and the other end is connected to the top surface of the brick body. The UHPC high-strength concrete casting body includes a first casting body, a second casting body, and a third casting body. The first casting body, the second casting body, and the third casting body are integrally cast and are all made of UHPC high-strength concrete. The first casting body is cast in the filling interval to connect adjacent bricks. The second casting body is cast in the U-shaped dovetail groove. The third casting body is cast on the outside of the three-dimensional curved brick body. It also includes multiple UHPC reinforcing wrappers and multiple connecting bolts. The UHPC reinforcing wrappers are cast and wrapped around the portion of the flexible connector that protrudes from the UHPC high-strength concrete casting and are fused and fixedly connected to the UHPC high-strength concrete casting. The top of the flexible connector is provided with a connecting hole, and the connecting bolt passes through the connecting hole and is fixedly connected to the keel frame. The diameter of the connecting hole is larger than the diameter of the connecting bolt.

2. The three-dimensional curved brick arch splicing unit according to claim 1, characterized in that: The thickness of the third casting body is 20-30mm.

3. The three-dimensional curved brick arch splicing unit according to claim 1, characterized in that: The keel frame is welded from bidirectional square steel pipes.

4. The three-dimensional curved brick arch splicing unit according to claim 1, characterized in that: It also includes multiple metal rods, the bottom end of which is used to be fixedly connected to the keel frame, and the top end of which is used to be fixedly connected to the concrete main structure.

5. The three-dimensional curved brick arch splicing unit according to claim 4, characterized in that: The top of the metal hanger is connected to the concrete body by means of fixing through the structural plate, fixing by welding of embedded parts, or fixing with post-installed expansion bolts.

6. A three-dimensional curved surface arch system, characterized in that: It includes multiple three-dimensional curved brick arch splicing units as described in any one of claims 1 to 5.

7. A method for manufacturing a three-dimensional curved surface arch system as described in claim 6, characterized in that: Includes the following steps: S1: Lay a large mold base plate on the horizontal site of the component factory, and build CNC-carved stiffening plates on the large mold base plate to form the mold; S2. The bricks are assembled on the mold according to the designed brick arrangement scheme, and rubber strips are fixed between adjacent bricks to form a filling gap between the bricks. S3. Embed flexible connectors, and pour UHPC high-strength concrete layer by layer between the bricks on the side away from the mold to form the UHPC high-strength concrete casting body. S4. Connect the flexible connector to the keel steel frame; S5. After the UHPC high-strength concrete pouring body has completely solidified, the keel steel frame is lifted for demolding. After demolding, the rubber strip is removed and the grout leakage on the surface of the brick body is cleaned. S6. Transport the completed three-dimensional curved brick arch splicing unit to the location where it needs to be installed, and connect the keel frame to the concrete main structure.

Images